WP2 will frame the current major novelties related to the product design and manufacturing technologies for glass-sealed industrial and medical microsystems. Based on the gathered information, new benchmarks and product design techniques will be investigated and merged with the technology design area. This will drive a new practice for product design called design by tech where the selection of the shape, material and final product properties takes into account the possible technologies to be used as enablers and a set of micro-FEM based rules. The objectives of WP2 will be to design a new generation of products together with developing the software environment for accomplishing the design tasks. WP2 will produce as an outcome the Mesomorph Design/Manufacturing-to-Lifevalue Platform which will enable a number of innovation actions:
New design principles, rules and prototypes driven by the technologies adopted.
Integrating in the micro-assembled system new items and features (e.g. sensors and microprocessors).
3Mapping the product requirements to the novel technologies capabilities.
4Design by tech products and round robin part family definition.
Integrating additional information supporting the efficient final assembly delivery.
WP3 will focus on the design of the Mesomorph process model. The Design/Manufacturing-to-Lifevalue Platform architecture realized in WP2 will be enriched with a number of rules and algorithms developed in the current work package. The objectives of WP3 are:
Design process parameters, multi-scale and multi-physic models for femto-based, 2PP and SADALP processes associated to Round Robin Parts.
Merge the process model with the machine behavioural model.
3Ensuring the transformation of CAD files to NC processable files.
4Identify the requirements for the heads as well as the handling, tooling and sensing systems to be configured in WP4-5-6.
WP4 will focus on the development of the three different modules conceiving the Mesomorph machine solution, starting from the product family description and the process design activities, outcomes of respectively WP2 and 3. The first module, conceiving the femto/2PP head, will be equipped with a high power laser source integrating a novel laser scanner solution in order to improve the performances of standard solution with respect to the complex and various products family. The second module, conceiving the SADALP head, will be designed in order to be toughen and enriched with respect to the current (but at the same time novel) solution; in order to do that a new and more flexible nozzle solution will be implemented, together with an improved and reliable piping infrastructure altogether with real-time temperature industrial control architecture. The last module, pertaining the micro-assembly pick&place portal, will be engineered in order to be able to manage the entire product portfolio safely (e.g. ESD compliant), precisely (<1um micron precision), and rapidly (up to 20m/min) adopting vacuum-based gripper solution and a robust serial Cartesian kinematic.
As a result, the objectives of WP4 are:
- Development of an innovative high-efficiency and high-beam-quality laser femto system suitable for ablation, surface texturing and 2PP equipped with a novel laser source and a more reliable and precise laser scanner as well as the set of appropriate optics in order to integrate all the monitoring devices coaxially with respect to the beam.
- Design and engineering a novel and robust SADALP head solution capable of deposit thin and precise reactants layers faster with current state-of-the-art solutions. The development of the head includes all the piping as well as auxiliary systems in order to manage the process effectiveness of the solution.
- Development of an accurate, fast and reliable pick&place portal capable to safely handle the entire product family and perform all the operations required (positioning, bonding, soldering) in order to get the micro-assembly done.
The mechatronic problem comprises the integration of the Mesomorph modules, developed among WP4, and the design of the machine architecture, which consists in the super-stiff basement. In Mesomorph, this activity will also face the challenge of integrating operations and processes extremely critical (at micro and macro scales) and traditionally carried out as multiple sequential process phases on different equipment. As Mesomorph is conceived to operate in highly dynamic production contexts where the family of products can change with regards to the volumes and technological requirements, this activity is structured to generate evolving mechatronic configuration solutions based on the modifiable use of modules accordingly to the lifecycle degradation status and the process needs. Consequently, a structured methodology for configuring the machine and customizing the mechatronic modules will be integrated with the dynamically assessing of the performance of the solution
An instrumental feature of Mesomorph solution refers to the capability to persistently monitor the process and the working environment and collecting and harmonizing information from sensors contributing to target the performance thresholds under the energy efficiency, product quality, productivity and process quality perspectives.
The overall goal of the current work-package is achieved by fulfilling the following scientific and technical objectives:
Develop smart sensing system architecture capable of monitoring, at a nano-scale level, the entire micro-assembly process and, at a macro-scale level, the machine.
Develop an advanced vision system composed of heterogeneous high speed cameras, accurate interferometers operating in the nanoscale range and imaging ellipsometry measurement system(s).
3Design a SW and HW infrastructure for data fusion and elaboration to be passed to the CAx chain.
This WP focuses on the realization of the software infrastructure to support the seamless product-process-machine data integration in a closed loop (CAx-CNC) chain which will enable a persistent monitoring and adaptation of the Mesomorph processes. This work will be executed in synergy with WP3 dealing with the CAx design and the process models and strategy definition and adaptation. In the current work-package it is made sure all the information are synthesized and exchanged persistently and efficiently. From the sensors and vision system data, managed as per T6.4, a quality analysis of the processes is performed while the machine is depositing, ablating or assembling the components in order to assess the results. The acquired data of the working part will enable the comprehension of its properties in terms of geometric compliancy as well as functional performances effectiveness. These properties, compared with the nominal values specified for the given product, will trigger, in case of misalignments, corrective actions on geometric adaptation or process-related functionalization of the product. In order to do that, the obtained geometry/quality KPIs is compared with the nominal CAD file and a limited subset of these data is then transferred to CAM packages where paths for re-manufacturing the product are decided; in the CAPP, processes parameters and process plans are added to the information in the CAM.
The information is then processed into a format understandable for CNC controllers and translated in logic and motion commands for the laser source, the SADALP head, the pick&place portal and the basement axes along with the heaters and auxiliaries. The overall goal of the current work-package is achieved by fulfilling the following scientific and technical objectives:
Organize the information associated to nominal CAD-CAM-CAPP and CNC with data collected from the sensing system.
Envisage possible misalignments between the nominal and actual patterns in every link of the CAx chain and efficiently transmit them in a form which is processable in closed loop by the CNC.
3Compute the entity of the misalignment/misgrowth/misdeposition/misbonding and execute the adaptation strategy.
he current work package concerns the configuration and development of the overall automation system for Mesomorph, its CNC as well as middleware infrastructure. Specifically, the main objectives are:
- The identification and modelling of the dynamics of the production environment to be controlled.
- The functional specification and development of high speed automation architecture and its adaptation logics.
- The design of the CNC architecture and adaptive control algorithms based on the process models.
- The development of an open middleware infrastructure.
The objectives of the current work package are:
- Integrating the Mesomorph machine in its all mechatronic modules and SW infrastructure.
- Efficiently managing the machine set-up and ramp-up.
- Defining of multi-level optimization and adaptation strategies.
- In line evaluation of the effective material property.
The focus of the current WP is to demonstrate the industrial application of Mesomorph solutions and validate the scientific and technological benefits with regards to the identified targeted industrial applications, certifying:
The feasibility of the Mesomorph 2PP, femto-based ablation, SADALP, bonding and manipulation process strategies.
The Mesomorph capability to produce a large product variety accomplishing productivity and high quality targets.
The dissemination and exploitation works aim at: